Building unit and method of manufacturing the same



Sept 12, 1933.

s. s. GIBNEY El AL BUILDING UNIT AND METHOD OF MANUFACTURING THE SAME Filed Nov. 25, 1931 INVENTOBJ, J'TEE/Vf J3 GUS/VF) ATTORNEYS.

' Patented Sept. 12, i933 1,926,093 I readers BWHNG UNIT AND METHOD tlliF MANU- FAUKUBING THE SAW dterne h. Gihney, Kansas Gity, Mo... and Herman Fluegel, it rains @flty, Karin.

Application November 25, will 7 Serial No. 577,216

ll Claims. (@11. 263-) This invention relates to building structures, abuts adjoining units and is owned to the wellthe units comprising the same, and the method known studding 10 of a building being constructed of manufacturing the unit. in accordance with the instant invention.

The primary object of the invention is the com The corner unit 12 is preferably pro-formed to s templationor a novel building unit having a surpresent a right angled member suitable for use so face simulating brick, tile or other heavy mateat the corners of the building. The component rial but formed in a unique manner to avoid using parts and broad idea of manufacturing this corthe actual heavy material in the ordinary manner. ner unit is much the same as planar unit 8 and One of the objects of the invention is to prowill be fully set down hereinafter. lo vide a substantially rectangular building unit in With specific regard to each unit 8 and its e5 sheet form that may be attached directly to the novel peculiarities, the same is made by employstudding of a new building frame or to the previing a base i l which should be a fibrous material ously'used siding of old structures. strong enough to carry a cementitious coating Another object of the instant invention is the 16 over one side and wherein is embedded a series is provision of aplanar building unit having straight of shallow bricks 18. One face of the bricks is 70 parallel sides and ends which abut the sides or exposed as illustrated and should have the apends of the adjoining unit in a manner to create proximate dimensions of a standard brick so far the appearance of an uninterrupted line or course as length and width are concerned. of briclr or tile. In the actual manufacture, the base 14 is cut so This invention further aims to provide a buildto size and overlaid with a cementitious coating 75 ing unit of the above generallcharacter that is 16 in plastic state. A suitable template is next efiective in creating the appearance of regular superimposed over the coating 16 which presents courses of brick, takes the place of briclr, stucco a guide for the placing of rectangular bricks 18. or ordinary wood siding and thoroughly insulates In pressing bricks 18 in place, a rectangular cavthe building with which it is associated. ity 20 is formed for each one and the arrangeso A yet further object of this invention is to proment is in series and end to end relation like the vide a building unit that is strong, durable and well-known courses of brick. in forcing the shah cheap to manufacture; that reduces the cost of low bricks 18 into cementitious coating 16 a ridge applying a siding to any building; that eliminates 22 is drawn up therebetween to present a mar the necessity of boxing and building paper; that tar joint of a size and appearance to simulate e5 weighs but little per square, and is lasting and such a joint between standard brick which have as weatherproof and free from maintenance rebeen set up in courses. uirements as any wall of brick, stone and ma- Bricks 18 that constitute a part of the unit asteriials of similar nature. sembly made in accordance with this invention Minor objects of the invention, including re may be molded of suitable materials and the finements of construction, method of manuf'acfaces 2% thereof sprinkled or otherwise provided turing and applying the unit, and flexibility in with granular substance such as slate, glass, porhandling will appear during the course of the celain or metal. The brick 18 is colored as re= following specification referring to the accomquired and variations or shading effects pro- 40 panying drawing wherein: duced through the substance thereon being mlect- Figure 1 is a perspective view of a portion of a ed for colors desired. building wall embodying this invention. When placing bricks 18, the end ones of alter- A Fig. 2 is a fragmentary face view of a pair of note or every other row must be thicker than the abutting building units. others and removed before the cementitious sub- 5' Fig. 3 is a vertical, fragmentary section along stance 16 has completely set. As a matter of fact, line m-nr of Fig. 2. and an alternate method of forming these end Fig. i is a perspective view of a fragment of a cavities of alternate rows, the template used corner member, and, should carry a block at these locations to lie Fig. 5 is a perspective view of one of the brick against the surface of base 14. Thus when this 50 faces 0! blocks entirely removed from its place block andtemplate are removed a cavity 26 is in the building unit. presented having a ridge 22 completely around Like reference characters are used herein to threesides of the same and having a bottom designate similar parts throughout the several formed by the base 14. This cavity 26 is at theviews of the drawing, and the numeral 8 indiend of alternate re s of cavities 20 and when the 55 cates a complete rectangular planar unit that ends of units 8 are abutting relation as shown no in the drawings, the two cavities 26 combine to form a cavity of equal length and width as the others of the units 8.

When units 8 are formed and ready for use, they are placed in abutting relation against the structure that is to support them and nails or other suitable fastening means 28 driven to position through base 14. If desired, holes may be formed from the bottom of cavities 26 to receive nails 28. After this securing operation takes place a brick 18 of suitable thickness is introduced into the long cavity formed by two cavities 26. The joint between the two units 8 is thus covered by the inserted brick and since the line of abutment is at the very end of the bricks between these cavities 26, no line here will show. Cement is used in fixing the inserted brick and an efiective tie is established to further produce a unitary wall. Obviously all evidence of fastening means 28 is eliminated.

Corner units 12 are handled like the planar units 8 and include a backing of sheet material 30 having insulating qualities like the base 14. A cementitious coating 32 has a series of brick members 34 therein between which are formed cavities 36 for the reception of the tie bricks previously described. It is notable that all of these cavities are substantially one-half the length of the long side of brick 18 or 34 as the case may be. Cavities 38 receive the two-sided bricks 34 and ridges 40 are established between the bricks as hereinabove mentioned.

In practice it is desirable to partially impregnate base 14 and 30 with waterproofing to add still another advantage to the structure.

Manifestly, boxing, builders paper, insulating material or any other similar parts of a building are not needed when making a structure in accordance with this invention. The side of the individual side or corner unit 8 and 12 respectively may be altered to suit requirements, and a multitude of effects are possible. Different sized units may be employed to cope with the location of openings for doors and windows. Breaks or imperfections in the joints between bricks l8 and 34 may be pointed in a manner like any wall and the lasting qualities of the structure embodying the invention are equal to walls using fullsized brick laid up in mortar in the established way.

Having thus described the invention, what isclaimed as new and desired to be secured by Letters Patent is:

1. A building unit comprising a base of sheet material; a cementitious coating overlying one side of said base and adhering thereto; a series of cavities formed in said cementitious material and a brick positioned in some of said cavities and projecting therefrom, each brick presenting an outstanding face in a plane spaced apart from the plane of said cementitious material surrounding said cavities.

2. A building unit comprising a base of sheet material; a cementitious coating overlying one side of said base and adhering thereto; a series of shallow cavities formed in the said cementitious material; a brick positioned in certain of said cavities; and fixtures continuing from the bottom 01 some of said cavities through the base, whereby to fasten said unit to supporting members.

' 3. A building unit comprising a base of sheet material; a cementitious coating overlying one side of said base; and a series of shallow rectangular cavities formed in the said cementitious material, said cavities arranged in straight rows and in end to end relation, alternate rows having their cavities onset and in overlapping relation to the cavities of adjacent rows.

4. A building unit comprising a base of sheet material having straight, continuous, parallel sides and straight continuous ends; a cementitious coating overlying one side of said base; and a series of cavities of uniform size arranged in rows parallel tothe sides of said base and extending from end to end of the base, the end cavities of alternate rows of cavities being substantially one-half the length of the others.

5. A building unit comprising a base of sheet material having straight, continuous, parallel sides and straight continuous parallel ends; a cementitious coating overlying one side of said base; a series of cavities arranged in rows parallel to the sides of said base and extending from end to end of the base; and holes continuing from the end cavities of alternate rows and formed through said base.

6. As a new article of manufacture, a building unit comprising a substantially rectangular base; a series of cavities formed in said base and arranged in rows across the face of said base; and a brick in'all of said cavities excepting the end cavities of alternate rows thereof.

7. A building unit comprising a planar base of insulating material; waterproofing impregnating said base; a cementitious coating overlying one side of said base and adhering thereto; a se- ,secured to said studding, each unit being substantially rectangular and abutting the adjoining unit along a straight line, brick receiving cavities formed in each unit and arranged in horizontal rows, the end cavities of alternate rows of each unit cooperating with the end cavities of adjoining units to form cavities of a size equal to the remaining cavities.

9. In a building structure, a number of spaced apart vertical studding; and a plurality of building units secured to said studding, the vertical abutting edges of adjoining units being straight and continuous from side to side of said unit at the center of one of said studding, a series of cavities formed in said units and arranged in 

